Process for production of pattern-forming body

ABSTRACT

A primary object of the present invention is to provide a process for the production of a pattern-forming body, the process enabling the formation of a highly precise pattern, requiring no post-exposure treatment and being free from a fear as to the deterioration of the pattern-forming body itself because no photocatalyst is contained in the produced pattern-forming body. In the present invention, the above problem can be solved by providing a process for the production of a pattern-forming body, the process comprising disposing a catalyst-containing layer-side substrate containing at least a photocatalyst-containing layer and a pattern-forming body substrate containing a characteristic-changeable layer which is changed in characteristics by the action of the photocatalyst in at least said photocatalyst-containing layer such that the photocatalyst-containing layer is in contact with the characteristic-changeable layer, followed by performing exposure to thereby change the characteristics of the exposed portion of the characteristic-changeable layer and thereafter dismounting the photocatalyst-containing layer-side substrate, thereby obtaining a pattern-forming body having a pattern which has been changed in characteristics on the characteristic-changeable layer.

BACKGROUND OF THE INVENTION

The present invention relates to a process for the production of a novelpattern-forming body usable in various applications including printing.

In the process for the production of pattern-forming bodies whereinvarious patterns such as designs, images, characters and circuits areformed on a substrate, various pattern-forming bodies are produced.

Explanations will be furnished taking the case of a printing process asan example. With regard to a planographic printing plate used forplanographic printing which is a kind of printing method, a planographicprinting plate having a pattern comprising a hydrophilic section whichaccepts ink and a section which does not accept any printing ink isproduced, an ink image to be printed on the hydrophilic section isformed by using the planographic plate and the formed image istransferred to, for example, paper to carry out printing. In suchprinting, a pattern such as characters and figures is formed on aprinting master plate to make a printing plate as a pattern-formingbody, which is installed on a printer and used. Various types have-beenproposed as a printing master plate for offset printing which is atypical planographic printing plate.

A printing plate for offset printing can be produced using, for example,a method in which a planographic printing master plate is exposedthrough a patterned mask and developed or a method in which a printingmaster plate is directly exposed using an electrophotographic system toplate-make directly on the printing master plate. An electrophotographicoffset printing master plate is produced using a method in which a lightconductive layer containing, as its major components, a light conductiveparticle such as zinc oxide and a binder resin is formed on a conductivesubstrate, this light conductive layer as a light-sensitive body isexposed using an electrophotographic system to form a highly hydrophilicimage on the surface of the light-sensitive body and in succession, thelight-sensitive body is treated using a fat-insensitizing solution tomake the non-image portion hydrophilic, thereby obtaining an offsetmaster plate, namely a pattern-forming body. The hydrophilic portion ismade lipophobic by dipping it in water or the like, printing ink isaccepted by the lipophilic image portion and the image portion istransferred to paper or the like. However, various post-exposuretreatments such as the treatment using a fat-insensitizing solution arerequired.

Also, a method of producing a planographic printing master plate hasbeen proposed, the method using a heat mode recording material capableof forming a pattern comprising a highly ink-acceptable section and anink-repellent section by laser radiation. The heat mode recordingmaterial has the characteristics that it does not require processs suchas a developing process and can produce a printing plate only by simplyforming an image by laser light. This recording material posesproblems-concerning the control of the strength of a laser, thetreatments of residuals such as solid-like materials denatured by alaser and printing durability.

Also, as a method for forming a highly precise pattern, methods of theproduction of a pattern-forming body using photolithography in which aphotoresist layer applied to a substrate is subjected to patternexposure, and in succession to the exposure, the photoresist isdeveloped and further etching is carried out or a photoresist is exposedto light by using a functional material as the photoresist to form anobjective pattern directly are known.

The method of forming a highly precise pattern using photolithography isused for the formation of a colored pattern of a color filter used inliquid crystal displays and the like, the formation of microlenses, theproduction of precise electric circuit substrates, the production of achrome mask used for pattern exposure and the like. However, aphotoresist is used and it is necessary to develop using a liquiddeveloper and to carry out etching after the exposure depending on thetypes of method. These methods therefore have the problem that anecessity of treating waste liquids arises. Also, when a functionalmaterial is used as the photoresist, there is the problem that thephotoresist is deteriorated by an alkaline solution and the like whichare used in a developing process.

Although a highly precise pattern of a color filter and the like isformed by printing or the like, the pattern formed by printing hasproblems concerning positional accuracy and it is therefore difficult toform a pattern with high accuracy.

Meanwhile, for instance, a method of producing a pattern-forming bodywherein a pattern is formed using a material which is changed inwettability by the action of a photocatalyst has been studied by theinventors of the present invention to solve such problems. However, theconventional methods of producing a pattern-forming body by the actionof a photocatalyst have the problems that there is a possibility of adeterioration caused by the photocatalyst depending on the type ofpattern-forming body because the photocatalyst is structurally containedin the pattern-forming body itself to be produced.

SUMMARY OF THE INVENTION

The present invention has been made in view of the foregoing problemsand it is an object of the present invention to provide a process forthe production of a pattern-forming body, the process being capable offorming a pattern with high accuracy, requiring no post-treatment afterexposure and being free from a fear as to the deterioration of thepattern-forming body itself because no photocatalyst is contained in theproduced pattern-forming body.

In order to attain the above object, the present invention provides aprocess for the production of a pattern-forming body, the processcomprising disposing a photocatalyst-containing layer-side substratecontaining at least a photocatalyst-containing layer and apattern-forming body substrate containing a characteristic-changeablelayer which is changed in characteristics by the action of thephotocatalyst contained in at least the photocatalyst-containing layersuch that the photocatalyst-containing layer is in contact with thecharacteristic-changeable layer, followed by performing exposure tothereby change the characteristics of the exposed portion of thecharacteristic-changeable layer and thereafter dismounting thephotocatalyst-containing layer-side substrate, thereby obtaining apattern-forming body having a pattern which has been changed incharacteristics on the characteristic-changeable layer.

As aforementioned, in the present invention, thephotocatalyst-containing layer and the characteristic-changeable layerare disposed such that they are in contact with-each other andthereafter the exposure is carried out to thereby change thecharacteristics of the exposed portion of the characteristic-changeablelayer thereby forming a pattern. Therefore, no post-exposure treatmentis needed and a pattern-forming body having a highly precise pattern canbe produced. Also, since the photocatalyst-containinglayer-side-substrate is dismounted from the pattern-forming body afterexposure, the photocatalyst-containing layer is not contained in thepattern-forming body itself and there is therefore no fear that thepattern-forming body is deteriorated with time by the action of thephotocatalyst.

In the present invention, the photocatalyst-containing layer-sidesubstrate comprises at least a transparent substrate and aphotocatalyst-containing layer and may be formed separately from thepattern-forming body substrate. Also, the photocatalyst-containinglayer-side substrate may be formed by coating thecharacteristic-changeable layer of the pattern-forming body substratewith a photocatalyst-containing layer.

In the case where the photocatalyst-containing layer-side substrate isformed as a body separated from the pattern-forming body substrate andcomprises at least the photocatalyst-containing layer and thetransparent substrate, this photocatalyst-containing layer-sidesubstrate is brought into contact with the characteristic-changeablelayer of the pattern-forming body substrate to carry out exposure toform a pattern on the characteristic-changeable layer by the action ofthe photocatalyst and then the photocatalyst-containing layer-sidesubstrate is dismounted, whereby the photocatalyst-containing layer-sidesubstrate can be used again. Namely, by allowing thephotocatalyst-containing layer-side substrate to have such a structure,pattern-forming bodies can be produced fundamentally by using thephotocatalyst-containing layer-side substrate repeatedly. This casetherefore has an advantage when many pattern-forming bodies are formedat a time.

On the other hand, in the case where the photocatalyst-containinglayer-side substrate is formed by coating the characteristic-changeablelayer of the pattern-forming body substrate with thephotocatalyst-containing layer, the photocatalyst-containing layer-sidesubstrate can be easily formed by only coating thecharacteristic-changeable layer with the photocatalyst-containing layer.This case is therefore advantageous when the number of the patternedbodies to be produced is small. In the case where thephotocatalyst-containing layer-side substrate is formed by coating thecharacteristic-changeable layer of the pattern-forming body substratewith the photocatalyst-containing layer in this manner, the dismountingof the photocatalyst-containing layer after exposure is carried outusing, for instance, a method of peeling it using an adhesive tape.

In the case where the photocatalyst-containing layer-side substrate isformed separately from the pattern-forming body substrate and comprisesat least the photocatalyst-containing layer-and the transparentsubstrate, the photocatalyst-containing layer-side substrate may beformed such that it is integrated with a photomask. This is because, ifthe photomask is formed in advance on the photocatalyst-containinglayer-side substrate, it is unnecessary to prepare the photomaskseparately and troublesome works, such as alignment with the photomask,which are conducted during exposure are eliminated.

Also, in the case where the photocatalyst-containing layer-sidesubstrate is formed separately from the pattern-forming body substrateand comprises at least the photocatalyst-containing layer and thetransparent substrate, the photocatalyst-containing later-side substratemay have a photocatalyst-containing layer which is formed pattern-wiseon the transparent substrate. This case also has the advantage that nophotomask is needed at the time of exposure. Also, because thephotocatalyst-containing layer-side substrate is changed incharacteristics only at the portion which is in contact with thepattern-forming body substrate at the time of exposure, light forexposure is not necessarily parallel light and even diffused light mayalso be used. This renders it possible to make the restriction on thelight source to the minimum.

In the process for the production of a pattern-forming body according tothe present invention, the photocatalyst to be contained in thephotocatalyst-containing layer is preferably one or two or more typesselected from titanium dioxide (TiO₂), zincoxide (ZnO), tinoxide (SnO₂),strontium titanate (SrTiO₃), tungstenoxide (WO₃), bismuth oxide (Bi₂O₃)and iron oxide (Fe₂O₃). The photocatalyst is preferably titanium dioxide(TiO₂) among these oxides. This is because titanium dioxide is effectiveas the photocatalyst since it has a high bandgap energy, it is alsochemically stable and nontoxic and it is also easily available.

In the present invention, the pattern-forming body substrate ispreferably formed from at least a substrate and the aforementionedcharacteristic-changeable layer formed on the substrate. This is becausethe characteristic-changeable layer is preferably formed as a thin filmon the substrate in view of strength, cost and function since thecharacteristic-changeable layer generally has various characteristics.

On the other hand, the above pattern-forming body substrate may beformed only of one characteristic-changeable layer. This is because ifit is a pattern-forming substrate having self-supportability, aparticular base material is not needed.

Further, the characteristic-changeable layer in the present invention ispreferably a wettability-changeable layer which is changed in surfacewettability by the action of the photocatalyst contained in thephotocatalyst-containing layer. The characteristics of thecharacteristic-changeable layer include various types and among thesevarious characteristics, a change in wettability is exemplified as oneof important characteristics. This reason is as follows. Specifically,the characteristic-changeable layer is designed to be awettability-changeable layer in this manner, whereby a pattern changedin wettability by the action of the photocatalyst can be formed on thepattern-forming body. By sticking a composition for functional portionssuch as ink to the portion changed in wettability, various functionalelements, for example, a color filter and a microlens can be formed asexplained later.

In the present invention, the above wettability-changeable layer ispreferably a wettability-changeable layer which is changed inwettability in a manner that the contact angle with water is lowered byexposure. This reason is as follows. Specifically, if such awettability-changeable layer which is changed in wettability in a mannerthat the contact angle with water is decreased by exposure is formed,the wettability of this layer is easily changed by performing exposureor the like to enable the formation of an ink-philic region reduced incontact angle with water. For example, only the portion to which acomposition for a functional portion is to be stuck can be made to be aink-philic region with ease. Therefore, color filters, microlenses andthe like can be produced in an efficient manner, which is economicallyadvantageous.

In the present invention, the contact angle of thewettability-changeable layer with water is preferably 90 degrees or morein the unexposed portion and 30 degrees or less in the exposed portion.When the contact angle with water is 90 degrees or less, onlyinsufficient ink-repellent ability is obtained because the unexposedportion is a portion where ink-repellency is needed and there is apossibility that a composition for a functional portion such as ink isleft unremoved. Therefore,a contact angle out of the defined range isundesirable. Also, the reason why the contact angle of the exposedportion with water is 30 degrees or less is that when the contact angleexceeds 30 degrees, there is a possibility that a composition forfunctional portions such as ink is inferior in spreading at thisportion, specifically, possibility is afforded for derivation ofdisadvantages such as the occurrence of color voids when the functionalportion is, for example, a pixel portion of a color filter.

Also, this wettability changeable layer is preferably a layer containingorganopolysiloxane. This reason is explained below. Specifically, in thepresent invention, the-characteristics required for thewettability-changeable layer are those that the wettability-changeablelayer is ink-repellent when it is not irradiated with light and becomesink-philic by the action of the photocatalyst in thephotocatalyst-containing layer when it is irradiated with light. As amaterial imparting such characteristics to the wettability-changeablelayer, organopolysiloxane is first exemplified.

Among the organopolysiloxanes, those which are hydrolytic condensates orhydrolytic cocondensates of one or two or more silicon compoundsrepresented by Y_(n)SiX_((4-n)) (wherein Y represents an alkyl group, afluoroalkyl group, a vinyl group, an amino group, a phenyl group or anepoxy group, X represents an alkoxyl group or a halogen and n denotes aninteger of 0 to 3) are preferable. This is because suchorganopolysiloxanes satisfy the requirements for the abovecharacteristics.

Also, in the present invention, the above organopolysiloxane ispreferably those containing a fluoroalkyl group. This polysiloxanecontaining a fluoroalkyl group can exhibit very high water-repellencyand oil-repellency at the non-irradiated portion.

In the present invention, the above characteristic-changeable layer maybe a decomposition-removable layer which is decomposed and removed bythe action of the photocatalyst contained in thephotocatalyst-containing layer. This reason is as follows. By designingthe characteristic-changeable layer to be the decomposition-removablelayer which can be decomposed and removed by the action of thephotocatalyst in the photocatalyst-containing layer-in this manner, theexposed portion is decomposed and removed by the action of thephotocatalyst resultantly. The portion irradiated with light isdecomposed and removed-completely in this manner without, particularly,a necessity of post-treatment. For this, this structure may be used invarious applications in which, for example, the decomposition-removablelayer is made of a photoresist and the photocatalyst-containinglayer-side substrate is brought into contact with the photoresist toperform exposure, whereby a pattern can be formed on the photoresistwithout a necessity of performing the developing process which isconventionally carried out.

In this case, it is preferable that the decomposition-removable layer bedifferent in contact angle with water from exposed members to be exposedwhen the decomposition-removable layer is decomposed and removed.

If the decomposition-removable layer and the exposed members to beexposed when the decomposition-removable layer is decomposed and removedare different from each other in contact angle with water in thismanner, the decomposition-removable layer in the exposed portion isdecomposed and removed by the action of the photocatalyst and theexposed member is eventually exposed from the surface. On the otherhand, in the unexposed portion, the decomposition-removable layer isleft unremoved. Here, in the case where the decomposition-removablelayer and the exposed members are different from each other in contactangle with water, for example, in the case where thedecomposition-removable layer is formed of an ink-repellent material andthe exposed member is formed of an ink-philic material, a portion wherea functional portion is to be formed is irradiated with light in advanceto make the photocatalyst work whereby the decomposition-removable layerin this portion can be removed with the result that the exposed portionis made to be a concave portion and an ink-philic region and theunexposed portion is made to be a convex portion and an ink-repellentregion. This ensures that a composition for functional portions can bestuck easily with high accuracy to the concave and ink-philic regionwhere this functional portion is to be formed. Therefore, the functionalportion can be formed more accurately than in the case where theaforementioned characteristic-changeable layer is thewettability-changeable layer. Also, it is unnecessary to carry outpost-exposure treatments such as a developing process and a washingprocess. For this, the process can be simplified easily and as a result,a functional element which is inexpensive and has precise functionalportion can be obtained.

Also, it is desirable that the contact angle of thedecomposition-removable layer with water be 60 degrees or more and thecontact angle, with-water, of the surface of the exposed member which isexposed when the decomposition-removable layer is decomposed and removedbe 30 degrees or less.

In the present invention, the decomposition-removable layer in theunexposed portion is left unremoved. Here, generally, the unexposedportion is a portion where ink-repellency is required. Therefore, whenthe contact angle of the decomposition-removable layer with water issmaller than 60 degrees, only insufficient ink-repellency is obtainedand there is a possibility that a composition for functional portions isleft unremoved. So, such a contact angle out of the defined range isundesirable.

On the other hand, the exposed portion is decomposed and removed by theaction of the photocatalyst in the photocatalyst-containing layer whichis in contact with the decomposition-removable layer. Therefore, in theexposed portion, the exposed member formed under thedecomposition-removable layer is eventually exposed from the surface.This portion is a portion for which ink-philic characteristics areusually required. Therefore, when the contact angle of the exposedmember with water exceeds 30 degrees, there is a possibility that acomposition for functional portions such as ink is inferior in spreadingat the function portion and possibility is afforded for occurrence ofvoids of the composition for functional portions.

As aforementioned, it is preferable that the decomposition-removablelayer be decomposed and removed by the photocatalyst in thephotocatalyst-containing layer which is in contact with thedecomposition-removable layer and have ink-repellency. Therefore, thedecomposition-removable layer preferably comprises hydrocarbon type,fluorine type or silicone type nonionic surfactant.

A pattern exposure method in the present invention may be a method usinga photomask or a method using light drawing irradiation and is properlyselected according to the qualities and applications of the resultingpattern-forming body. Also, the exposure is preferably carried out whilethe photocatalyst-containing layer is heated as described. This isbecause the exposure of the photocatalyst-containing layer under heatallows the photocatalyst in the photocatalyst-containing layer to act onthe characteristic-changeable layer highly sensibly.

In order to solve the aforementioned problem, the present inventionfurther provides a photocatalyst-containing layer-side substrate for theproduction of a pattern-forming body, the substrate comprising at leasta transparent substrate and a photocatalyst-containing layer, wherein acharacteristic-changeable layer of a pattern-forming substrate havingthe characteristic-changeable layer which is changed in characteristicsby the action of the photocatalyst on the surface thereof and thephotocatalyst-containing layer are exposed while the both layers arebeing in contact with each other to form a pattern-forming body.

As aforementioned, the photocatalyst-containing layer-side substrate forthe production of a pattern-forming body according to the presentinvention ensures that a pattern can be formed on the pattern-formingbody by exposing the photocatalyst-containing layer while thephotocatalyst-containing layer is in contact with thecharacteristic-changeable layer of the pattern-forming substrate.Therefore, the photocatalyst-containing layer-side substrate for theproduction of a pattern-forming body according to the present inventionhas the advantage that it can be repeatedly used basically bydismounting it from the characteristic-changeable layer after exposed.In this case, the photocatalyst contained in thephotocatalyst-containing layer is preferably titanium dioxide. This isbecause titanium dioxide is effective as the photocatalyst since it hasa high bandgap energy, it is also chemically stable and nontoxic and itis also easily available.

The above photocatalyst-containing layer-side substrate for theproduction of a pattern-forming body may be formed such that it isintegrated with a photomask and may also have a photocatalyst-containinglayer formed pattern-wise on a transparent substrate. These reasons areas aforementioned.

In order to solve the above problem, the present invention also providesa pattern-forming body comprising at least a substrate and acharacteristic-changeable layer which is formed on the substrate and hasa pattern which has been changed in characteristics by the action of aphotocatalyst and having no photocatalyst-containing layer.

As aforementioned, the pattern-forming body of the present inventioncomprises at least the substrate and the characteristic-changeable layerhaving the pattern which has been changed in characteristics by theaction of the photocatalyst. Therefore, when the change incharacteristics is, for example, a change in wettability, thispattern-forming body may be utilized as various printing master platesmaking use of a difference in the acceptability of ink and is thereforemade into various inexpensive printing master plates which need not toperform, for example, developing and washing process when they areproduced. Also, since this pattern-forming body does not comprise aphotocatalyst-containing layer, it has an advantage that there is nofear that the pattern-forming body is deteriorated with time by theaction of the photocatalyst.

In the present invention, the characteristic-changeable layer ispreferably a wettability-changeable layer which is to be changed inwettability by the action of the photocatalyst under exposure such thatthe contact angle with water is lowered.

If the characteristic-changeable layer is the wettability-changeablelayer which is to be changed in wettability by the action of thephotocatalyst under exposure such that the contact angle with water islowered as aforementioned, the wettability is easily changed byperforming exposure to form a pattern-forming body having a pattern ofan ink-philic region having a small contact angle with water. Bysticking a composition for functional portions to the pattern of theink-philic region of the pattern-forming body, functional elements suchas color filters and microlenses can be formed efficiently, presenting acost advantage.

Also, it is preferable that the characteristic-changeable layer is adecomposition-removable layer which is decomposed and removed by theaction of the photocatalyst and the decomposition-removable layer isdifferent in contact angle with water from the exposed member which isexposed when the decomposition-removable layer is decomposed andremoved.

As aforementioned, the pattern-forming body is made to have a structurein which the characteristic-changeable layer is adecomposition-removable layer which is decomposed and removed by theaction of the photocatalyst and the decomposition-removable layer isdifferent in contact angle with water from the exposed member which isexposed when the decomposition-removable layer is decomposed andremoved, whereby a pattern-forming body can be obtained in which theportion where the functional portion is to be formed is made to be anink-philic region such that the contact angle of the portion with waterwhich-contact angle indicates the wettability of the portion is madesmall in advance and the other portions are made to be an ink-repellentregion having a large contact angle with water. By sticking acomposition for functional portions to the pattern of the ink-philicregion of the pattern-forming body, the composition for functionalportions can be stuck easily only to the ink-philic region having asmall contact angle with water. Therefore, in the same manner as in theaforementioned case where the characteristic-changeable layer is thewettability-changeable layer, functional elements can be formed easilyfrom the pattern-forming body without performing post-exposuretreatments such as a developing process and a washing process. For this,the process can be simplified with ease and functional elements havingfunctional portions can be obtained at low costs.

In the present invention, functional portions are disposed at thesections corresponding to the pattern formed on the aforementionedpattern-forming body, whereby a functional element can be made. The useof the pattern-forming body of the present invention makes it possibleto obtain functional elements with ease in this manner. At this time,the functional portion may be a metal. In this case, these functionalelements maybe used as metal circuits or the like.

In this case, the functional element preferably has a structure in whichthe pattern is a pattern formed of sections differing in contact anglewith water and the functional portions are formed on sections having asmall contact angle with water in this pattern. This is because, asaforementioned, functional elements can be formed with ease by allowinga composition for functional portions to adhere to the ink-philic regionhaving a small contact angle with water and therefore these functionalelements are advantageous in view of cost.

The functional element of the present invention may be made as a colorfilter by using the functional portion as a pixel portion and as amicrolens by using the functional portion as a lens. This is because theadvantage of the present invention can be utilized sufficiently when thefunctional element of the present invention is used as the color filterand microlens.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1(A) to FIG. 1(C) and FIG. 1(C′) are typical sectional viewsshowing one example of a process for the production of a pattern-formingbody according to the present invention.

FIG. 2(A) to FIG. 2(D) and FIG. 2(D′) are typical sectional viewsshowing another example of a process for the production of apattern-forming body according to the present invention.

FIG. 3 is a typical sectional view for explaining a process for theproduction of a functional element according to the present invention.

FIG. 4 is a typical sectional view for explaining a process for theproduction of a functional element according to the present invention.

FIG. 5 is a typical sectional view for explaining a process for theproduction of a functional element according to the present invention.

FIG. 6(A) to FIG. 6(C) are typical sectional views for explaining aprocess for the production of a functional element according to thepresent invention.

FIG. 7(A) to FIG. 7(D) are typical sectional views for explaining aprocess for the production of a functional element according to thepresent invention.

FIG. 8(A) to FIG. 8(C) are typical sectional views for explaining aprocess for the production of a microlens according to the presentinvention.

FIG. 9(A) to FIG. 9(C) are typical sectional views for explaining aprocess for the production of a functional element according to thepresent invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

A process for the production of a pattern-forming body according to thepresent invention will be hereinafter explained in detail. The processfor the production of a pattern-forming body according to the presentinvention comprises disposing a catalyst-containing layer-side substratecontaining at least a photocatalyst-containing layer and apattern-forming body substrate containing a characteristic-changeablelayer which is changed in characteristics by the action of thephotocatalyst in at least the photocatalyst-containing layer such thatthe photocatalyst-containing layer is in contact with thecharacteristic-changeable layer, followed by performing exposure tothereby change the characteristics of the exposed portion of thecharacteristic-changeable layer and thereafter dismounting thephotocatalyst-containing layer-side substrate, thereby obtaining apattern-forming body having a pattern which has been changed incharacteristics on the characteristic-changeable layer.

As aforementioned, in the process for the production of apattern-forming body according to the present invention, thephotocatalyst-containing layer and the characteristic-changeable layerare disposed such that they are in contact with each other andthereafter the exposure is carried out to thereby change thecharacteristics of the exposed portion of the characteristic-changeablelayer by the action of the photocatalyst, thereby forming a pattern madeof the exposed portion on the characteristic-changeable layer, namely,the portion changed in characteristics. Therefore, post-exposuretreatments such as developing and washing are not needed and therefore apattern can be formed using processs smaller in number than those in aconventional process at low costs. Accordingly, functional elements suchas a color filter can be formed easily at low costs by formingfunctional portions along the pattern of the pattern-forming body.

Further, in the present invention, after the characteristics of thecharacteristic-changeable layer are changed by the action of thephotocatalyst contained in the photocatalyst-containing layer, thephotocatalyst-containing layer side substrate is dismounted to preparethe pattern-forming body-side substrate as a pattern-forming body andtherefore no photocatalyst-containing layer is contained in theresulting pattern-forming body. Therefore, when a functional portion isformed in the pattern-forming body to be obtained to form a functionalelement, no photocatalyst-containing layer is contained in the inside ofthe functional element and therefore, possibilities that the functionalelement is deteriorated with time by the action of the photocatalyst canbe eliminated entirely.

The process of the formation of a pattern-forming body according to thepresent invention as aforementioned will be explained with reference tothe drawings. The pattern in the present invention represents variouspatterns such as designs, images, circuits and characters and noparticular limitation is imposed on the pattern.

FIG. 1 shows an example of the process for the production apattern-forming body according to the present invention. In thisproduction process, first a photocatalyst-containing layer-sidesubstrate 3 consisting of a transparent substrate 1 and aphotocatalyst-containing layer 2 formed on the transparent substrate 1and a pattern-forming body substrate 6 consisting of a substrate 4 and acharacteristic-changeable layer 5 formed on the substrate 4 are prepared(see FIG. 1(A)).

Next, the photocatalyst-containing layer 2 of thephotocatalyst-containing layer-side substrate 3 is stuck to thecharacteristic-changeable layer 5 of the pattern-forming body substrate6 such that the both layers are in contact with each other and exposedto light, for example, UV light through a photomask 7. Thecharacteristics of the exposed section on the characteristic-changeablelayer 5 are changed and the exposed section is converted into acharacteristic-changeable section 8 (see FIG. 1(B)).

Next, the photocatalyst-containing layer-side substrate 3 is dismounted(separated) from the pattern-forming body substrate to thereby form apattern-forming body 9 in which the pattern of thecharacteristic-changeable section 8 is formed (see FIG. 1(C)).

Also, another example of the process of the production of apattern-forming body according to the present invention is shown in FIG.2. In this example, first a pattern-forming body substrate 6 in which acharacteristic-changeable layer 5 is formed on a substrate 4 is prepared(see FIG. 2(A)). Next, a photocatalyst-containing layer 2 is formed onthis characteristic-changeable layer by application or the like (seeFIG. 2(B)). In this example, the photo-catalyst-containing layer 2formed by application or the like becomes the photocatalyst-containinglayer-side substrate 3. Then, the substrate 3 is exposed to lightthrough a photomask 7 in the same manner as in the above example 1 tothereby form a characteristic-changeable section 8 on thecharacteristic-changeable layer 5 (see FIG. 2(C)). Finally, thephotocatalyst-containing layer 2 is dismounted to obtain apattern-forming body 9 in which the pattern of thecharacteristic-changeable section 8 has been formed on thecharacteristic-changeable layer 5 (see FIG. 2(D)).

The process for the production of a pattern-forming body according tothe present invention will be hereinafter explained in detail taking theaforementioned two production processes as examples.

(Photocatalyst-Containing Layer-Side Substrate)

In the present invention, the photocatalyst-containing layer-sidesubstrate includes any substrate as far as it contains at least aphotocatalyst-containing layer. For example, thephotocatalyst-containing layer-side substrate may be those containing atransparent substrate 1 besides the photocatalyst-containing layer 2 asshown by the example of FIG. 1 or those formed of a singlephotocatalyst-containing layer 2 as shown by the example of FIG. 2.Also, the photocatalyst-containing layer-side substrate may be thoseprovided with other layers according to the need.

Also, this photocatalyst-containing layer-side substrate is obtained byforming the photocatalyst-containing layer 2 on the transparentsubstrate 1 as shown by the example of FIG. 1 and may be a substrateformed separately from the pattern-forming body substrate in advance ora substrate formed such that it is integrated with the pattern-formingbody substrate such as the photocatalyst-containing layer-side substrateobtained by forming the photocatalyst-containing layer 2 by applicationas shown by the example of FIG. 2.

If, as shown in FIG. 1, the photocatalyst-containing layer-sidesubstrate 3 is formed separately from the pattern-forming body substrate6, the photocatalyst-containing layer-side substrate 3 can be used againby dismounting the photocatalyst-containing layer-side substrate 3 afterthe characteristic-changeable layer of the pattern-forming bodysubstrate 6 and the photocatalyst-containing layer-side substrate 3 areexposed to light in a manner that the both layers are in contact witheach other to form a pattern on the characteristic-changeable layer 5 bythe action of the photocatalyst as shown in FIG. 1(A) to (C).Specifically,the photocatalyst-containing layer-side substrate can berepeatedly used fundamentally by allowing the photocatalyst-containinglayer-side substrate to have such a structure, presenting an advantagewhen many pattern-forming bodies are produced.

In the case of forming the photocatalyst-containing layer-side substrateseparately from the pattern-forming body substrate, it is preferable tocontain at least a transparent substrate other than thephotocatalyst-containing layer in light of strength, cost and the like.Specifically, such a structure in which the photocatalyst-containinglayer 2 is formed on the transparent substrate 1 as shown in FIG. 1makes it possible to have strength sufficient to stand against repeateduse and is more advantageous in cost than in the case where only thephotocatalyst-containing layer 2 is formed separately.

Such a photocatalyst-containing layer-side substrate may have anystructure as far as it has at least a photocatalyst-containing layer anda transparent substrate and is provided with an exposed portion on onesurface. For example, other than the above, a photomask may be formedsuch that it is integrated with the substrate or a protective layer maybe formed on the periphery. Also, in FIG. 1(B), a contact-inhibitivelayer is formed mask-pattern-wise on the photocatalyst-containing layerto limit the portion, which is in contact with thecharacteristic-changeable layer, pattern-wise so that acharacteristic-changeable section can be formed pattern-wise on thecharacteristic-changeable layer even if the entire surface of thecharacteristic-changeable layer is exposed to light. Also thephotocatalyst-containing layer itself may be formed pattern-wise.

To specifically state the case where the photomask is formed in anintegrated form, a photomask with the shading portion formedpattern-wise is formed such that it is integrated with thephotocatalyst-containing layer-side substrate. The position of thephotomask in this case may be any position of thephotocatalyst-containing layer-side substrate as far as it allowspattern exposure on the pattern-forming body substrate to be performedproperly by carrying out exposure from any side of thephotocatalyst-containing layer-side substrate. The integration of thephotomask has the advantage that the alignment of the photomask is notrequired at the time of exposure in addition to the advantage that it isunnecessary to prepare any photomask separately.

Also, those prepared by forming the photocatalyst-containing layeritself pattern-wise are those, for example, having aphotocatalyst-containing layer patterned by a photolithographic methodor the like after the photocatalyst-containing layer is applied to theentire surface of a transparent substrate. Such a structure in which thephotocatalyst-containing layer is formed pattern-wise on the transparentsubstrate in this manner has the advantage that it is unnecessary to useparallel light when the above exposure is carried out besides theadvantage that it is unnecessary to use a photomask at the time ofexposure. Therefore, it is possible to widen a space for the selectionof an exposure light source.

On the other hand, as shown in FIG. 2, when the photocatalyst-containinglayer-side substrate is made in the form integrated with thepattern-forming body substrate 6 by applying thephotocatalyst-containing layer to the pattern-forming body substrate 6,no strength is required for the photocatalyst-containing layer-sidesubstrate and therefore a layer for keeping strength is not needed,which is advantageous when a small number of pattern-forming bodies isprepared.

In this case, also, any other layers may be formed as far as at leastthe photocatalyst-containing layer is contained. For example, anadhesive layer may be disposed in advance to make it easy to dismountthe photocatalyst-containing layer-side substrate. Also, thisphotocatalyst-containing layer may be formed pattern-wise.

(Photocatalyst-Containing Layer)

As aforementioned, the photocatalyst-containing layer-side substrate 3contains at least the photocatalyst-containing layer 2.

There is no particular limitation to the photocatalyst-containing layeras far as it has a structure in which the photocatalyst containedtherein changes the characteristics of the characteristic-changeablelayer which is in contact with the photocatalyst-containing layer. Thephotocatalyst-containing layer may be those structured of aphotocatalyst and a binder or those prepared by forming a film of asingle photocatalyst. Also, as to the wettability of the surface of thephotocatalyst-containing layer, the surface may be either ink-philic orink-repellent.

Although the working mechanism of the photocatalyst represented bytitanium dioxide as will be explained later is not entirely clear, it isgenerally considered that carriers generated by the radiation of lightreacts directly with neighboring compounds or combines with activeoxygen analogues produced in the presence of oxygen and water to exertan influence on the change of the chemical structures of organiccompounds. It is considered that in the present invention, this carrieracts on the compounds contained in the characteristic-changeable layerwhich is in contact with the photocatalyst-containing layer.

Examples of the photocatalyst to be used in the present invention mayinclude those known as photo-semiconductors such as titanium dioxide(TiO₂), zinc oxide (ZnO), tin oxide (SnO₂), strontium titanate (SrTiO₃),tungsten oxide (WO₃), bismuth oxide (Bi₂O₃) and iron oxide (Fe₂O₃). Oneor two or more types selected from these compounds may be mixed andused.

In the present invention, particularly titanium dioxide (TiO₂) ispreferably used since it has a high bandgap energy, it is chemicallystable and nontoxic and it is also easily available. Titanium dioxideincludes an anatase type and a rutile type and any one of these typesmay be used in the present invention. However, anatase type titaniumdioxide is preferable. The exciting wavelength of anatase type titaniumdioxide is present at 380 nm or less.

Examples of such anatase type titanium dioxide include hydrochloricacid-deswelling anatase type titania sol (STS-02 (average particlediameter: 7 nm), manufactured by Ishihara Sangyo Kaisha, Ltd.) and(ST-K01, manufactured by Ishihara Sangyo Kaisha, Ltd.) and nitricacid-deswelling anatase type titania sol (TA-15 (average particlediameter: 12 nm), manufactured by Nissan Chemical Industries, Ltd.).

A smaller particle diameter of the photocatalyst is more preferablebecause a photocatalyst reaction is caused efficiently. An averageparticle diameter of 50 nm or less is preferable and the use of aphotocatalyst having an average particle diameter of 20 nm or less isparticularly preferable.

The photocatalyst-containing layer in the present invention may be thoseformed of a single photocatalyst or those formed by mixing aphotocatalyst with a binder.

Examples of a method used when the photocatalyst-containing layer isformed of a single photocatalyst in the case of using titanium dioxideinclude a method in which amorphous titania is formed on a transparentsubstrate or a characteristic-changeable layer and is thenphase-converted into a crystalline titania by calcination. The aboveamorphous titania used here may be obtained, for example, by thehydrolysis and dehydration condensation of inorganic salts of titaniumsuch as titanium tetrachloride or titanium sulfate or by the hydrolysisand dehydration condensation of organic titanium compounds such astetraethoxytitanium, tetraisopropoxytitanium, tetra-n-propoxytitanium,tetrabutoxytitanium or tetramethoxytitanium in the presence of an acid.Then, the obtained amorphous titania can be denatured into anatase typetitania by calcination at 400° C. to 500° C. and into rutile typetitania by calcination at 600° C. to 700° C.

Also, in the case of using a binder, binders having such a high bindingenergy as to prevent the major skeleton of the binder from beingdecomposed by light excitation of the aforementioned photocatalyst arepreferable. Examples of such a binder include organopolysiloxane whichwill be explained in detail in the paragraph for explaining thewettability-changeable layer as described later.

When organopolysiloxane is used as the binder in this manner, the abovephotocatalyst-containing layer may be formed by dispersing aphotocatalyst, organopolysiloxane as the binder and, as required, otheradditives in a solvent to prepare a coating solution and by coating onthe transparent substrate or on the characteristic-changeable layer withthe coating solution. As the solvent to be used, alcoholic organicsolvents such as ethanol and isopropanol are desirable. The coating maybe carried out using known coating methods such as spin coating, spraycoating, dip coating, roll coating and beads coating. When aultraviolet-curable component is contained as the binder, ultravioletrays are applied to perform hardening treatment wherebyphotocatalyst-containing layer may be formed.

Also, an amorphous silica precursor may be used as the binder. Thisamorphous silica precursor is preferably silicon compounds representedby the formula SiX₄, wherein X is a halogen, a methoxy group, an ethoxygroup or an acetyl group, silanol which is dehydrates of these siliconcompounds and polysiloxane having an average molecular weight of 3000 orless.

Specific examples include tetraethoxysilane, tetraisopropoxysilane,tetra-n-propoxysilane, tetrabutoxysilane and tetramethoxysilane. In thiscase, the amorphous silica precursor and photocatalyst particles areuniformly dispersed in a nonaqueous solvent and the amorphous silicaprecursor is hydrolyzed by water in air to form silanol on a transparentsubstrate. The resulting silanol is then dehydrated andcondensation-polymerized at ambient temperature, whereby thephotocatalyst-containing layer can be formed. If the dehydration andcondensation-polymerization of silanol are carried out at 100° C. ormore, the degree of polymerization of silanol is increased, making itpossible to improve the strength of the film surface. These bindingagents maybe used either singly or by mixing two or more.

The content of the photocatalyst contained in thephotocatalyst-containing layer is designed to be in a range from 5 to60% by weight and preferably 20 to 40% by weight. The thickness of thephotocatalyst-containing layer is preferably in a range from 0.05 to 10μm.

Also, the photocatalyst-containing layer may contain a surfactantbesides the aforementioned photocatalyst and binder. Specific examplesof the surfactant include nonionic surfactants such as hydrocarbon typesurfactants, e.g., each series of NIKKOL BL, BC, BO and BB manufacturedby Nikko Chemicals and fluorine type or silicone type nonionicsurfactants, e.g., ZONYL, FSN and FSO manufactured by DuPont, SarfronS-141 and 145 manufactured by Asahi Glass, Megafac F-141 and 144manufactured by Dainippon Ink & Chemicals Inc., Ftergent F-200 and F251manufactured by Neosu, Unidine DS-401 and 402 manufactured by DaikinIndustries and Flowlad FC-170 and 176 manufactured by 3 M. Also,cationic surfactants, anionic surfactants and amphoteric surfactants maybe used.

Further, the photocatalyst-containing layer may contain, besides theabove surfactant, oligomers or polymers such as polyvinyl alcohol,unsaturated polyester, acrylic resins, polyethylene, diallyl phthalate,ethylenepropylenediene monomers, epoxy resins, phenol resins,polyurethane, melamine resins, polycarbonate, polyvinyl chloride,polyamide, polyimide, styrene-butadiene rubber, chloroprene rubber,polypropylene, polybutylene, polystyrene, polyvinyl acetate, polyester,polybutadiene, polybenzimidazole, polyacrylnitrile, epichlorohydrin,polysulfide and polyisoprene.

(Transparent Substrate)

In the present invention, as shown in FIG. 1, thephotocatalyst-containing layer-side substrate 3 preferably comprises thetransparent substrate 1 and the photocatalyst-containing layer 2 formedon the transparent substrate 1.

No particular limitation is imposed on this transparent substrate as faras it is a material which transmits light such as UV light so as toenable exposure from the side of the photocatalyst-containing layer-sidesubstrate on which side the photocatalyst-containing layer 2 is notformed when exposure is performed as shown in FIG. 1(B). Preferableexamples of transparent substrate materials include non-flexibletransparent rigid materials such as quarts glass, Pyrex® glass andsynthetic quartz plates and flexible transparent materials such astransparent resin films and optical resin plates.

(Pattern-Forming Body Substrate)

In the process for the production of a pattern-forming body according tothe present invention, as shown in FIG. 1 and FIG. 2, first theaforementioned photocatalyst-containing layer-side substrate 3 and thepattern-forming body substrate 6 are prepared.

No particular limitation is imposed on the pattern-forming bodysubstrate as far as it has at least a characteristic-changeable layer.To state in more detail, the pattern-forming body substrate may beformed only of one characteristic-changeable layer if thecharacteristic-changeable layer has self-supporting ability or may be atype provided with the characteristic-changeable layer formed on asubstrate in light of strength. Also, in addition, another protectivelayer or the like may be formed according to the need. However, it isnecessary that the characteristic-changeable layer is exposed from allor apart of the surface.

In the present invention, the pattern-forming body substrate shows thesubstrate put in the condition that any pattern made ofcharacteristic-changeable sections has not been formed yet on thecharacteristic-changeable layer and one in which a pattern of thecharacteristic-changeable sections is formed on thecharacteristic-changeable layer by exposing this pattern-forming bodysubstrate to light is referred to as the pattern-forming body.

(Characteristic-Changeable Layer)

Any layer may be used as the characteristic-changeable layer in thepresent invention as far as it is changed in characteristics by theaction of the photocatalyst. For example, the characteristic-changeablelayer may be a layer which is colored by the action of the photocatalystby mixing a photochromic material such as spiropyran or by mixing anorganic dye or the like which is decomposed by the action of thephotocatalyst in the characteristic-changeable layer.

Also, as the characteristic-changeable layer, a layer maybe used whichis improved in adhesion to various materials by using a polymer materialsuch as a polyolefin, e.g., polyethylene or polypropylene, to introducea polar group into the exposed portion and to place the surface in roughcondition by the action of the photocatalyst. If such anadhesion-changeable layer which is changed in adhesion is used as thecharacteristic-changeable layer in this manner, a highly adhesivepattern can be formed by pattern exposure. The pattern-forming bodyhaving a pattern of such a highly adhesive section ensures that, forexample, a metal thin film pattern can be formed by depositing a metalcomponent on the pattern-forming body to form a metal thin film and thenpeeling off the metal thin film by using, for example, adhesives orchemicals by making use of a difference in adhesion. According to thismethod, a metal thin film pattern can be formed without forming anyresist pattern and therefore print boards, electronic circuit elementsand the like having a more highly precise pattern than those produced bya printing method can be formed.

As aforementioned, there is no particular limitation to thecharacteristic-changeable layer insofar as it is a layer having variouscharacteristics which are changed by the action of the photocatalyst.However, in the present invention, the following two cases arepreferable among the aforementioned various characteristic-changeablelayers because in these two cases, the effectiveness of the presentinvention is drawn out more greatly in relation to, particularly, theresulting functional elements. Specifically, in one case, thecharacteristic-changeable layer is a wettability-changeable layer whichis changed in wettability by the action of the photocatalyst to form apattern of wettabilities and in another case, thecharacteristic-changeable layer is a decomposition-removable layer whichis decomposed and removed by the action of the photocatalyst to form apattern of irregularities.

(Wettability-Changeable Layer)

The wettability-changeable layer meant in the present invention is alayer which is changed in the wettability of the surface by the actionof the photocatalyst during exposure to enable the formation of apattern of the sections differing in wettability. Thiswettability-changeable layer is preferably a layer which is changed inwettability by exposure such that it is reduced in contact angle withwater, though no particular limitation is imposed on thewettability-changeable layer.

As aforementioned, the wettability-changeable layer is made to have sucha structure in which it is changed in wettability by exposure such thatthe contact angle with water is decreased. This structure ensures thatthe wettability is easily changed by performing pattern exposure withthe result that a pattern of ink-philic regions reduced in contact anglewith water can be formed. Accordingly, for example, only the sectionswhere functional portions are to be formed on the wettability-changeablelayer are exposed to thereby change the sections to ink-philic regions,easily. So a functional element can be formed with ease by sticking acomposition for functional portions to the portion. Thus, functionalelements can be produced efficiently, which is advantageous in view ofcost.

Here, the ink-philic region device a region which has a small contactangle with water and exhibits high wettability to a composition forfunctional portions, for example, coloring ink and compositions for theformation of microlenses. Also, the ink-repellent region device a regionwhich has a large contact angle with water and exhibits low wettabilityto coloring ink and compositions for the formation of microlenses.

The contact angle of the aforementioned wettability-changeable layerwith water is 90 degrees or more and preferably 140 degrees or more atthe unexposed portion. This reason is that when the contact angle withwater is 90 degrees or less, only insufficient ink-repellency isobtained and the possibility that a composition for functional portions,such as coloring ink, is left unremoved arises, because the unexposedportion is a portion for which ink-repellency is required in the presentinvention.

Also, the above wettability-changeable layer is preferably a layer whichis decreased in contact angle with water to 30 degrees or less andpreferably 20 degrees or less when exposed. The reason why the contactangle of the exposed portion with water is designed to be 30 degrees orless is that when the contact angle exceeds 39 degrees, there is apossibility that a composition for functional portions such as coloringink is inferior in spreading at this portion and possibility is affordedfor occurrence of defects of functional portions.

The contact angle with water meant here is indicated by a value measuredusing a contact angle-measuring meter (CA-Z type, manufactured by KyowaKaimen Kagaku) 30 seconds after water droplets are dropped from amicrosyringe.

There is no particular limitation to a material used for thewettability-changeable layer as far as it has the aforementionedcharacteristics relating to wettability, specifically it is a materialwhich is changed in wettability by the photocatalyst contained in thephotocatalyst-containing layer which is in contact with thewettability-changeable layer when it is exposed, and has a primary chainwhich is resistant to deterioration and decomposition caused by theaction of the photocatalyst. Examples of the material include (1)organopolysiloxane which is obtained by hydrolysis andpolymerization-condensation of chloro or alkoxysilane by a sol-gelreaction or the like and (2) organopolysiloxane such as those obtainedby crosslinking high water-repellent or oil-repellent silicone. Theseorganopolysiloxanes preferably have a fluoroalkyl group.

In the case of the above (1), organopolysiloxanes which are hydrolyzedcondensates or hydrolyzed co-condensates of one or two or more siliconcompounds represented by the formula:Y_(n)SiX_((4-n))

wherein y represents an alkyl group, a fluoroalkyl group, a vinyl group,an amino group, a phenyl group or an epoxy group, X represents analkoxyl group, acetyl group or a halogen and n denotes an integer of 0to 3. Here, the number of carbons of the group represented by Y ispreferably in a range from 1 to 20 and the alkoxy group represented by Xis preferably a methoxy group, ethoxy group, propoxy group or butoxygroup.

Examples of the alkoxy group which may be used includemethyltrichlorosilane, methyltribromosilane, methyltrimethoxysilane,methyltriethoxysilane, methyltriisopropoxysilane,methyltri-t-butoxysilane; ethyltrichlorosilane, ethyltribromosilane,ethyltrimethoxysilane, ethyltriethoxysilane, ethyltriisopropoxysilane,ethyltri-t-butoxysilane; n-propyltrichlorosilane,n-propyltribromosilane, n-propyltrimethoxysilane,n-propyltriethoxysilane, n-propyltriisopropoxysilane,n-propyltri-t-butoxysilane; n-hexyltrichlorosilane,n-hexyltribromosilane, n-hexyltrimethoxysilane, n-hexyltriethoxysilane,n-hexyltriisopropoxysilane, n-hexyltri-t-butoxysilane;n-decyltrichlorosilane, n-decyltribromosilane, n-decyltrimethoxysilane,n-decyltriethoxysilane, n-decyltriisopropoxysilane,n-decyltri-t-butoxysilane; n-octadecyltrichlorosilane,n-octadecyltribromosilane, n-octadecyltrimethoxysilane,n-octadecyltriethoxysilane, n-octadecyltriisopropoxysilane,n-octadecyltri-t-butoxysilane; phenyltrichlorosilane,phenyltribromosilane, phenyltrimethoxysilane, phenyltriethoxysilane,phenyltriisopropoxysilane, phenyltri-t-butoxysilane; tetrachlorosilane,tetrabromosilane, tetramethoxysilane, tetraethoxysilane,tetrabutoxysilane, dimethoxydiethoxysilane; dimethyldichlorosilane,dimethyldibromosilane, dimethyldimethoxysilane, dimethyldiethoxysilane;diphenyldichlorosilane, diphenyldibromosilane, diphenyldimethoxysilane,diphenyldiethoxysilane; phenylmethyldichlorosilane,phenylmethyldibromosilane, phenylmethyldimethoxysilane,phenylmethyldiethoxysilane; trichlorohydrosilane, tribromohydrosilane,trimethoxyhydrosilane, triethoxyhydrosilane, triisopropoxyhydrosilane,tri-t-butoxyhydrosilane; vinyltrichlorosilane, vinyltribromosilane,vinyltrimethoxysilane, vinyltriethoxysilane, vinyltriisopropoxysilane,vinyltri-t-butoxysilane; trifluoropropyltrichlorosilane,trifluoropropyltribromosilane, trifluoropropyltrimethoxysilane,trifluoropropyltriethoxysilane, trifluoropropyltriisopropoxysilane,trifluoropropyltri-t-butoxysilane;γ-glycidoxypropylmethyldimethoxysilane,γ-glycidoxypropylmethyldiethoxysilane,γ-glycidoxypropyltrimethoxysilane, γ-glycidoxypropyltriethoxysilane,γ-glycidoxypropyltriisopropoxysilane,γ-glycidoxypropyltri-t-butoxysilane;γ-methacryloxypropylmethyldimethoxysilane,γ-methacryloxypropylmethyldiethoxysilane,γ-methacryloxypropyltrimethoxysilane,γ-methacryloxypropyltriethoxysilane,γ-methacryloxypropyltriisopropoxysilane,γ-methacryloxypropyltri-t-butoxysilane;γ-aminopropylmethyldimethoxysilane, γ-aminopropylmethyldiethoxysilane,γ-aminopropyltrimethoxysilane, γ-aminopropyltriethoxysilane,γ-aminopropyltriisopropoxysilane, γ-aminopropyltri-t-butoxysilane;γ-mercaptopropylmethyldimethoxysilane,γ-mercaptopropylmethyldiethoxysilane, γ-mercaptopropyltrimethoxysilane,γ-mercaptopropyltriethoxysilane, γ-mercaptopropyltriisopropoxysilane,γ-mercaptopropyltri-t-butoxysilane;β-(3,4-epoxycyclohexyl)ethyltrimethoxysilane,β-(3,4-epoxycyclohexyl)ethyltriethoxysilane; and partially hydrolyzedproducts of these compounds; and mixtures of these products.

Particularly, polysiloxane containing a fluoroalkyl group is preferablyused. Specific examples of the polysiloxane include hydrolyzedcondensates or hydrolyzed co-condensates of one or two or more of thefollowing fluoroalkylsilanes. Those which are generally known asfluorine type silane coupling agents may be used.

-   -   CF₃(CF₂)₃CH₂CH₂Si(OCH₃)₃;    -   CF₃(CF₂)₅CH₂CH₂Si(OCH₃)₃;    -   CF₃(CF₂)₇CH₂CH₂Si(OCH₃)₃;    -   CF₃(CF₂)₉CH₂CH₂Si(OCH₃)₃;    -   (CF₃)₂CF(CF₂)₄CH₂CH₂Si(OCH₃)₃;    -   (CF₃)₂CF(CF₂)₆CH₂CH₂Si(OCH₃)₃;    -   (CF₃)₂CF(CF₂)₈CH₂CH₂Si(OCH₃)₃;    -   CF₃(C₆H₄)C₂H₄Si(OCH₃)₃;    -   CF₃(CF₂)₃(C₆H₄)C₂H₄Si(OCH₃)₃;    -   CF₃(CF₂)₅(C₆H₄)C₂H₄Si(OCH₃)₃;    -   CF₃(CF₂)₇(C₆H₄)C₂H₄Si(OCH₃)₃;    -   CF₃(CF₂)₃CH₂CH₂SiCH₃(OCH₃)₂;    -   CF₃(CF₂)₅CH₂CH₂SiCH₃(OCH₃)₂;    -   CF₃(CF₂)₇CH₂CH₂SiCH₃(OCH₃)₂;    -   CF₃(CF₂)₉CH₂CH₂SiCH₃(OCH₃)₂,    -   (CF₃)₂CF(CF₂)₄CH₂CH₂SiCH₃(OCH₃)₂;    -   (CF₃)₂CF(CF₂)₆CH₂CH₂SiCH₃(OCH₃)₂;    -   (CF₃)₂CF(CF₂)₈CH₂CH₂SiCH₃(OCH₃)₂;    -   CF₃(C₆H₄)C₂H₄SiCH₃(OCH₃)₂;    -   CF₃(CF₂)₃(C₆H₄) C₂H₄SiCH₃(OCH₃)₂;    -   CF₃(CF₂)₅(C₆H₄) C₂H₄SiCH₃(OCH₃)₂;    -   CF₃(CF₂)₇(C₆H₄) C₂H₄SiCH₃(OCH₃)₂;    -   CF₃(CF₂)₃CH₂CH₂Si(OCH₂CH₃)₃;    -   CF₃(CF₂)₅CH₂CH₂Si(OCH₂CH₃)₃;    -   CF₃(CF₂)₇CH₂CH₂Si(OCH₂CH₃)₃;    -   CF₃(CF₂)₉CH₂CH₂Si(OCH₂CH₃)₃; and    -   CF₃(CF₂)₇SO₂N(C₂H₅)C₂H₄CH₂Si(OCH₃)₃

The use of the polysiloxane containing such a fluoroalkyl group asaforementioned greatly improves the ink-repellency of the unexposedportion of the wettability-changeable layer and allows thewettability-changeable layer to develop the function to prevent thesticking of the composition for functional portions such as coloringink.

Examples of the above reactive silicone (2) may include compounds havingthe skeleton represented by the following formula:

wherein n denotes an integer of 2 or more, R¹ and R² respectivelyrepresent a substituted or unsubstituted alkyl, alkenyl, aryl orcyanoalkyl group having 1 to 10 carbon atoms wherein 40% or less by molratio of the total mols is vinyl, phenyl and halogenated phenyl. Also,those in which R¹ and R² are methyl groups are preferable because thesurface energy is the smallest and the content by mol ratio of methylgroups is preferably 60% or more. Also, at least one or more reactivegroups such as a hydroxyl group are contained in a molecular chain atthe chain terminal or the side chain.

A stable organosilicone compound, such as dimethylpolysiloxane, whichdoes not participate in a crosslinking reaction may be mixed togetherwith the aforementioned organopolysiloxane.

The wettability-changeable layer in the present invention may furthercontain a surfactant. Specific examples of the surfactant includenonionic surfactants such as hydrocarbon type surfactants, e.g., eachseries of NIKKOL BL, BC, BO and BB manufactured by Nikko Chemicals andfluorine type or silicone type nonionicsurfactants, e.g., ZONYL, FSN andFSO manufactured by Du Pont, Sarfron S-141 and 145 manufactured by AsahiGlass, Megafac F-141 and 144 manufactured by Dainippon Ink & ChemicalsInc., Ftergent F-200 and F251 manufactured by Neosu, Unidine DS-401 and402 manufactured by Daikin Industries and Flowlad FC-170 and 176manufactured by 3 M. Also, cationic surfactants, anionic surfactants andamphoteric surfactants may be used. Also, cationic surfactants, anionicsurfactants and amphoteric surfactants may be used.

Further, the wettability-changeable layer may contain, besides the abovesurfactant, oligomers or polymers such as polyvinyl alcohol, unsaturatedpolyester, acrylic resins, polyethylene, diallyl phthalate,ethylenepropylenediene monomer, epoxy resins, phenol resins,polyurethane, melamine resins, polycarbonate, polyvinyl chloride,polyamide, polyimide, styrene-butadiene rubber, chloroprene rubber,polypropylene, polybutylene, polystyrene, polyvinyl acetate, polyester,polybutadiene, polybenzimidazole, polyacrylnitrile, epichlorohydrin,polysulfide and polyisoprene.

Such a wettability-changeable layer may be formed by dispersing theaforementioned components together with, as required, other additives ina solvent to prepare a coating solution, which is then applied tosubstrate. As the solvent to be used, alcoholic organic solvent such asethanol and isopropanol are desirable. The coating may be carried outusing a known coating method such as spin coating, spray coating, dipcoating, roll coating and beads coating. In addition, in the case wherea ultraviolet ray-curable component is contained, ultraviolet rays areapplied to carry out hardening treatment, whereby thewettability-changeable layer can be produced.

In the present invention, the thickness of the wettability-changeablelayer is preferably 0.001 μm to 1 μm and particularly preferably in arange from 0.01 to 0.1 μm in view of change rate of wettability which ischanged by the photocatalyst.

In the present invention, the use of the wettability-changeable layerhaving the aforementioned components ensures that the wettability of theexposed portion is changed, making use of actions such as oxidation anddecomposition of organic groups and additives which are parts of theabove components by the action of the photocatalyst contained in thephotocatalyst-containing layer which is in contact with thewettability-changeable layer, to make the wettability-changeable layerink-philic, making it possible to cause a large difference inwettability between the exposed portion and the unexposed portion.Therefore, by improving acceptability (ink-philic ability) and repulsiveability (ink-repellency) for compositions for functional portions suchas coloring ink, functional elements such as color filters which havehigh qualities and are advantageous in view of cost can be obtained.

(Decomposition-Removable Layer)

Next, explanations will be added as to the decomposition-removablelayer. This decomposition removable-layer has the characteristics thatthe decomposition-removable layer of the exposed portion is decomposedand removed by the action of the photocatalyst contained in thephotocatalyst-containing layer when exposed to light. For example, inFIG. 1, when the characteristic-changeable layer 5 is thedecomposition-removable layer, the characteristic-changeable sectionshown in FIG. 1(C) is eventually decomposed and removed by the action ofthe photocatalyst and the pattern of the decomposition-removable layer10, that is, the decomposition-removable layer 10 is removed as shown inFIG. 1(C′), with the result that a pattern-forming body in which theunderlying substrate 4 is exposed and a pattern of irregularities isformed can be obtained. Also, in FIG. 2, similarly, a pattern-formingbody can be obtained in which the decomposition-removable layer 10 onthe substrate 4 is removed so that the substrate 4 is exposed and apattern of irregularities is formed (see FIG. 2(D′)).

Since, in the decomposition-removable layer, the exposed portion isdecomposed and removed by the action of the photocatalyst asaforementioned, a pattern consisting of sections where thedecomposition-removable layer exists and sections where nodecomposition-removable layer exists, namely a pattern havingirregularities can be formed without performing a developing process anda washing process. Therefore, materials, such as various printing masterplates, requiring a pattern of irregularities can be formed with ease bythis method. Also, because the decomposition-removable layer of theexposed portion can be decomposed and removed by forming thisdecomposition-removable layer by application on a screen and allowingthe decomposition-removable layer to be in contact with thephotocatalyst-containing layer-side substrate to carry out patternexposure, a master plate for screen printing can be formed withoutperforming developing and washing processs. Moreover, when thisdecomposition-removable layer is formed using a material having thecharacteristics of a resist, a pattern of a resist can be formed byallowing the decomposition-removable layer to be in contact with thephotocatalyst-containing layer-side substrate to carry out patternexposure. It is therefore possible to use this decomposition-removablelayer as a photoresist which does not require a developing process and awashing process in, for example, a process for the production of asemiconductor.

It is to be noted that since this decomposition-removable layer is, forexample, oxidation-decomposed and vaporized by the action of thephotocatalyst excited by exposure to light, it is removed withoutperforming any particular after-treatment such as developing and washingprocesss; however, a washing process and the like may be carried outdepending on the type of material used for the decomposition-removablelayer.

In the case where the decomposition-removable layer is used, not onlyirregularities are formed but also a pattern can be formed based on adifference in characteristics between the exposed member which isexposed by the decomposition-removal operation and thedecomposition-removal layer. Examples of such characteristics mayinclude various types such as adhesion and color developing ability.Among these characteristics, wettability may be exemplified in thisinvention. It is preferable to form a pattern based on a difference inwettability in the point of effectiveness in the case of forming anelement finally.

Specifically, in the present invention, a structure is preferred inwhich the decomposition-removable layer is different in the contactangle with water from the exposed member which is exposed when thisdecomposition-removable layer is decomposed and removed. It is morepreferable that, particularly, the contact angle of thedecomposition-removable layer with water be larger than the contactangle of the exposed member with water. It is particularly preferablethat the contact angle of the decomposition-removable layer with waterbe 60 degrees or more.

This reason is as follows. Specifically, in the present invention, theunexposed portion is a portion where the decomposition-removable layerremains, namely the unexposed portion becomes a convex portion.Therefore, it is more preferable to stick the composition for functionalportions to the concave portion where the decomposition-removable layeris removed and the exposed member is exposed than to the convex portion.For this, the decomposition-removable layer preferably exhibitsink-repellency so as to be resistant to the sticking of the compositionfor functional portions thereto. So it is preferable that the contactangle of the decomposition-removable layer with water be larger than thecontact angle of the exposed member with water. When the contact angleof the decomposition removable layer with water is smaller than 60degrees, only insufficient ink-repellency is obtained, affordingpossibility for a presence of the residue of the composition forfunctional portions such as coloring ink and therefore such a contactangle out of the above defined range is undesirable.

Materials used for this decomposition-removable layer are those havingthe aforementioned characteristics required for thedecomposition-removable layer; specifically, those which are decomposedand removed by the action of the photocatalyst which is excited byexposure and contained in the photocatalyst-containing layer which is incontact with the decomposition-removable layer and preferably thosehaving a contact angle of 60 degrees or more with water.

Examples of these materials include hydrocarbon type, fluorine type orsilicone type nonionic surfactants. Specific examples of thesesurfactants include polyoxyethylene alkyl ether, polyoxyethylenealkylphenyl ether, perfluoroalkylethylene oxide adducts andperfluoroalkylamine oxide.

Examples of such a material available as hydrocarbon type nonionicsurfactants include each series of NIKKOL BL, BC, BO and BB (trademarks,manufactured by Nippon Surfactant Industries) and examples of a materialavailable as fluorine type or silicone type nonionic surfactants includeZONYL, FSN and FSO (trademark, manufactured by Du Pont), Sarfron S-141and 145 (trademark, manufactured by Asahi Glass), Megafac F-141 and 144(trademark, manufactured by Dainippon Ink & Chemicals Inc.), FtergentF-200 and F251 (trademark, manufactured by Neosu), Unidine DS-401 and402 (trademark, manufactured by Daikin Industries) and Flowlad FC-170and 176 (trademark, manufactured by 3 M.

Also, cationic surfactants, anionic surfactants and amphotericsurfactants may be used as the material for the decomposition-removablelayer. Specific examples of these surfactant for thedecomposition-removable layer may include sodium alkylbenzenesulfonate,alkyltrimethylammonium salts, perfluoroalkyl carboxylate,perfluoroalkylbetaine.

Further, as the material for the decomposition-removable layer, variouspolymers or oligomers besides the above surfactant maybe used. Examplesof these polymers and oligomers may include polyvinyl alcohol,unsaturated polyester, acrylic resins, polyethylene, diallyl phthalate,ethylenepropylenediene monomers, epoxy resins, phenol resins,polyurethane, melamine resins, polycarbonate, polyvinyl chloride,polyamide, polyimide, styrene-butadiene rubber, chloroprene rubber,polypropylene, polybutylene, polystyrene, polyvinyl acetate, nylon,polyester, polybutadiene, polybenzimidazole, polyacrylnitrile,epichlorohydrin, polysulfide and polyisoprene. Among these compounds, anink-repellent polymer having a high contact angle with water such aspolyethylene, polypropylene, polystyrene or polyvinyl chloride ispreferably used in the present invention.

Such a decomposition-removable layer may be formed by dispersing theaforementioned components together with, as required, other additives ina solvent to prepare a coating solution, which is then applied to thesubstrate or the exposed member (the substrate and the exposed membermay be common with each other). The coating may be carried out using aknown coating method such as spin coating, spray coating, dip coating,roll coating and beads coating.

In the present invention, the thickness of the decomposition-removablelayer is preferably 0.001 μm to 1 μm and particularly preferably in arange from 0.01 to 0.1 μm in view of decomposition rate which is changedby the photocatalyst.

(Substrate)

In the process for the formation of a pattern-forming body according tothe present invention, the characteristic-changeable layer is preferablyformed on the substrate 4 as shown in FIG. 1 and FIG. 2 in considerationof strength and final functional elements. Examples of the substrate mayinclude glass, metals such as aluminum and its alloys, plastics, fabricsand nonwoven fabrics according to the use of the pattern-forming body orfunctional elements formed using the pattern-forming body.

Also, when the characteristic-changeable layer is thedecomposition-removable layer as aforementioned, an exposed member maybe interposed between the substrate and the decomposition-removablelayer. This exposed member is, as mentioned above, a member to beexposed when the decomposition-removable layer is decomposed and removedby the action of the photocatalyst excited by exposure to light and ispreferably formed of a material differing in characteristics from thedecomposition-removable layer. As aforementioned, particularly in thecase where the above characteristics are wettability, a material havinga contact angle of 30 degrees or less with water is preferable. Asexamples of materials meeting the above requirements, inorganicmaterials such as glass ceramics and polymer materials whose surfacesare processed by hydrophilic treatment using a plasma or a couplingagent may be given.

It is to be noted that in the present invention, it is unnecessary todispose the exposed member separately when the above substrate has afunction as the exposed member.

(Contact Between the Photocatalyst-Containing Layer and theCharacteristic-Changeable Layer)

In the present invention, as shown in FIG. 1(B) and FIG. 2(C), it isnecessary to dispose the photocatalyst-containing layer 2 of thephotocatalyst-containing layer-side substrate 3 and thecharacteristic-changeable layer 5 of the pattern-forming body substrate6 such that the both layers are in contact with each other duringexposure.

Here, the “contact” meant in the present invention implies the conditionof the photocatalyst-containing layer disposed such that the action ofthe photocatalyst substantially extends to the characteristic-changeablelayer, including the condition of the photocatalyst-containing layerwhich is formed by application and stuck to thecharacteristic-changeable layer as shown in FIG. 2(C), the condition ofthe photocatalyst-containing layer which is actually brought intocontact with the characteristic-changeable layer as shown in FIG. 1(B)and further the case where even if, for example, there is no actualcontact between these layers, water, air or the like intervenes betweenthese layers so that the action of the photocatalyst contained in thephotocatalyst-containing layer extends to the characteristic-changeablelayer. In the present invention, such a contact condition may be kept atleast only during exposure.

(Exposure)

In the present invention, after the photocatalyst-containing layer 2 ofthe photocatalyst-containing layer-side substrate 3 and thecharacteristic-changeable layer 5 of the pattern-forming body substrate6 such that these layers are in contact with each other, exposure iscarried out as shown in FIG. 1(B) and FIG. 2(C).

The formation of a pattern by exposure in the present invention may beattained by exposure to light through the photomask 7 as shown in FIG.1(B) and FIG. 2(c) or by light drawing irradiation using laser light orthe like.

In the case of using the above photomask, a fine pattern can be formedby using a reduction projection printing method for reducing a maskpattern image with a reduction optical system. As such a photomask,those formed on a metal plate such as a deposition mask, those formed ofmetal chrome on a glass plate and the like may be used and aplate-making film may be used in printing applications.

On the other hand, in the case of light drawing irradiation using laserlight, a predetermined pattern may be directly drawn by using apredetermined drawing irradiation system without using a photomask.

The wavelength of light used for the exposure is usually designed to bein a range of 400 nm or less and preferably 380 nm or less but notlimited to this range. For example, it is possible to make thecharacteristic-changeable layer sensitive to visible light and to lighthaving other wavelengths by doping with ions of a metal such as chrome,platinum or palladium or by adding a fluorescent material or alight-sensitive dye. Examples of such a dye include cyanine dyes such asa cyanine dye, carbocyanine dye, dicarbocyanine dye and hemicyanine dye.Examples of other useful dyes may include crystal violet,triphenylmethane dyes such as basic fuchsine, diphenylmethane dyes,xanthene dyes such as Rhodamine B, Victoria Blue, Brilliant Blue,Malachite Green, Methylene Blue, pyrylium salts, benzopyrylium salts,trimethinebenzopyrylium salts and triallylcarbonium salts.

Examples of a light source which may be used for the exposure mayinclude a mercury lamp, metal halide lamp, xenon lamp, excimer lamp,excimer laser, YAG laser and other various light sources.

The exposure dose at the time of exposure is designed to be the exposuredose required to change the characteristics of thecharacteristic-changeable layer by the action of the photocatalyst. Atthis time, the sensitivity can be raised by carrying out exposure whileheating the photocatalyst-containing layer. This is importantparticularly when light drawing irradiation is used.

It is to be noted that although the exposure is performed from the sideof the photocatalyst-containing layer-side substrate 3 in the examplesshown in FIG. 1(B) and FIG. 2(C), the direction of the exposure is notlimited to the above in the present invention and exposure from the sideof the pattern-forming body substrate 4 is allowed if the substrate 4and the characteristic-changeable layer 5 transmit light.

The exposure performed in this manner brings about the result that theexposed characteristic-changeable layer 5 is changed to thecharacteristic-changeable section 8 formed pattern-wise as shown in FIG.1(B) and FIG. 2(C). The characteristic-changeable portion is awettability-changeable section if the characteristic-changeable layer isthe wettability-changeable layer, is a section differing in adhesion ifthe characteristic-changeable layer is the adhesion-changeable layerchanged in adhesion and is a section where a concave portion is formedif the characteristic-changeable layer is the decomposition-removablelayer which is to be decomposed and removed.

(Dismounting of the Photocatalyst-Containing Layer-Side Substrate)

In the present invention, as shown in FIG. 1(C) and FIG. 2(D), thepattern-forming body 9 is obtained in which a pattern of thecharacteristic-changeable section 8 is formed on thecharacteristic-changeable layer 5 by dismounting thephotocatalyst-containing layer-side substrate 3 after exposure.

With regard to the dismount of the photocatalyst-containing layer-sidesubstrate in the present invention, if, for example, thephotocatalyst-containing layer-side substrate is simply in contact withthe characteristic-changeable layer as shown in FIG. 1, it can bedismounted by simply separating the photocatalyst-containing layer-sidesubstrate 3 from the pattern-forming body 9, whereas if, for example,the photocatalyst-containing layer-side substrate 3 is stuck to thepattern-forming body as shown in FIG. 2, it is necessary to peel off thephotocatalyst-containing layer-side substrate by using an adhesive tape.

(Pattern-Forming Body)

The pattern-forming body thus obtained has a structure in which apattern of characteristic-changeable section is formed on thecharacteristic-changeable layer. Therefore, when the characteristics ofthe characteristic-changeable layer are wettability, the section whichhas been changed in wettability is changed in acceptability for printingink and therefore the pattern-forming body can be used as a printingplate. When the pattern-forming body of the present invention is used asa printing master plate, this has the effects that it is unnecessary toperform wet developing and the like and the production of the printingplate is completed at the same time when exposure is completed.

Also, when the characteristic-changeable layer is thedecomposition-removable layer, the exposed portion is decomposed andremoved by the action of the photocatalyst, so that the pattern-formingbody becomes a pattern having irregularities. The pattern having theseirregularities therefore may be used as various printing master platesand the like. Also, when the substrate is a screen and thedecomposition-removable layer is formed as the characteristic-changeablelayer on the screen, the exposed portion is decomposed and removed sothat a pattern-forming body consisting of stuffed portions and voidportions of the screen can be obtained and can be used as a screenprinting master plate.

Functional Elements

Moreover, various functional elements can be obtained by disposingfunctional portions on the sections corresponding to the pattern formedon the pattern-forming body.

Here, the functionality implies various functions such as opticalfunctions (e.g., light-selective absorption, reflecting characteristics,polarizability, light-selective transmittance, nonlinear optics,luminescence including fluorescence and phosphorescence and photochromiccharacteristics), magnetic functions (e.g., hard magnetism, softmagnetism, non-magnetism and magnetic permeability), electric orelectronic functions (e.g., conductivity, insulation, piezo-electriccharacteristics, pyroelectric characteristics and dielectriccharacteristics), chemical functions (e.g., adsorbing ability, desorbingability, catalytic ability, water-absorbing ability, ion conductivity,oxidation-reduction ability, electrochemical characteristics andelectrochromic characteristics), mechanical functions (e.g., wearresistance), thermal functions (e.g., heat conductivity, heat insulationand infrared radiation ability) and biological functions (e.g.,biological adaptability and anti-thrombogenic ability.

There are various methods to dispose such functional portions on thesections corresponding to the pattern of the pattern-forming bodydepending on the characteristics of the characteristic-changeable layer.When the characteristic-changeable layer is, for example, theadhesion-changeable layer which is changed in adhesion, a patternchanged in adhesion has been formed on the pattern-forming body.Therefore, a metal pattern as the functional portions is formed on onlyhighly adhesive portions by depositing a composition for functionalportions such as a metal over the entire surface of thecharacteristic-changeable layer and thereafter peeling off the depositedfilm by using an adhesive or the like. Circuits or the like can bethereby formed with ease.

When the characteristic-changeable layer is the decomposition-removablelayer, a pattern which has been changed in irregularities is formed.Accordingly, functional portions can be disposed easily at sectionscorresponding to the pattern by inserting and sticking a composition forfunctional portions to the concave portions. In this case, when there isa difference in wettability between the concave portions and the convexportions, specifically if the concave portions are highly wettableink-philic regions and the convex portions are less wettableink-repellent regions, the composition for functional portions can beinserted and stuck more easily.

When the characteristic-changeable layer is the wettability-changeablelayer, a pattern which has been changed in wettability is formed.Therefore, if a composition for functional portions is applied to thepattern-forming body, the composition for functional portions is stuckto only highly wettable ink-philic regions. Therefore, the functionalportions can be disposed with ease at the sections corresponding to thepattern of the pattern-forming body. In this case, it is desirable thatthe unexposed portion of the pattern-forming body have a criticalsurface tension of 50 mN/m or less and preferably 30 mN/m or less.

The types of composition for functional portions used in the presentinvention largely differ depending on the functions of functionalelements and methods for the formation of functional elements asaforementioned. In the case of forming a metal pattern on the basis of adifference in, for example, adhesion, the composition for functionalportions is a metal. Also, in the case of using the pattern-formingbodies changed in wettability or irregularities, compositionsrepresented by ultraviolet-curable monomers and the like which are notdiluted with a solvent or liquid compositions diluted with a solvent maybe used. In the case of the liquid composition diluted with a solvent,the solvent is preferably water, ethylene glycol or the like, whichexhibits high surface tension. Also, as the viscosity of the compositionfor functional portions is decreased, the pattern can be formed in ashorter time and therefore the characteristic-changeable layer isparticularly preferably a wettable-changeable layer. On the other hand,in the case of the liquid composition diluted with a solvent, a rise inviscosity and a change in surface tension caused by the vaporization ofthe solvent take place during the formation of the pattern and thesolvent is therefore preferably less volatile.

The composition for functional portions to be used in the presentinvention may be those which become the functional portions by stickingthem to the pattern-forming body to dispose them or those which becomethe functional portions after treated by chemicals, ultraviolet rays,heat and the like after disposed on the pattern-forming body. In thiscase, if a component cured by ultraviolet rays, heat, electron rays orthe like is contained as the binding agent used for the composition forfunctional portions, this is preferable because the functional portionscan be formed rapidly by performing hardening treatment.

A process for the formation of a functional element will be explained indetail. When the characteristic-changeable layer is, for example, thewettability-changeable layer, the composition for functional portionsforms functional portions on the pattern of the ink-philic regions,formed on the pattern-forming body, by using a coating device such asdip coating, roll coating, blade coating or spin coating or by a meanssuch as nozzle jetting device including an ink jet. As shown in FIG. 3,examples of the process may include a method in which a composition 11for functional portions is applied using a blade coater 10 on thepattern-forming body 9 provided with the characteristic-changeablesections (ink-philic regions) a formed by pattern exposure in thecondition that the characteristic-changeable layer 5 formed on thesubstrate is brought into contact with the photocatalyst-containinglayer and a method in which the composition 11 for functional portionsis dripped on the similar pattern-forming body 9 and applied by a spincoater 12 as shown FIG. 4. When the composition 11 for functionalportions is applied in this manner, the composition for functionalportions is stuck to only the characteristic-changeable sections 8 whichhave been changed in wettability and become ink-philic regions as shownin FIG. 5. This composition for functional portions is cured to form afunctional portion 13, whereby a functional element can be formed.

Moreover, if the pattern-forming body of the present invention is usedin a method of forming a metal film by electroless plating, functionalelements having a metal film pattern as the functional portions can beobtained. This is also an effective method when thecharacteristic-changeable layer is the wettability-changeable layer. Afunctional element having a desired pattern on thecharacteristic-changeable layer can be obtained by treating only theink-philic regions of the pattern-forming body having a pattern whichhas been changed in wettability by using a pretreating solution forchemical plating and then dipping the treated pattern-forming body in achemical plating solution. According to this method, print boards andelectronic circuit elements can be produced as functional elementsbecause a metal pattern can be formed without forming a resist pattern.

Also, the functional portions may be formed along a pattern by removingunnecessary portions by making use of a difference in characteristicsbetween the exposed portion and the unexposed portion after thecomposition for functional portions are disposed over the entire surfaceas mentioned above. This is an effective method particularly when thecharacteristic-changeable layer is the adhesion-changeable layer. Forexample, after an adhesive tape is stuck, unnecessary portions areremoved by after-treatments such as peeling treatment for peeling offthe adhesive tape, air-blowing treatment and treatment using a solventto enable the preparation of a pattern of the functional portions. Givenas examples of a method for disposing functional portions on the entiresurface as aforementioned are vacuum film-forming device such as PVD andCVD. Specifically, the composition 11 for functional portions is formedover the entire surface of the pattern-forming body 9 in which thecharacteristic-changeable layer 5 having a pattern of the characteristicchangeable sections 8 is formed on the substrate 4 by using afilm-forming device 14 utilizing vacuum such as CVD as shown in FIG.6(A). Examples of a method of removing the unnecessary portions of thecomposition 11 for functional portions formed over the entire surface inthis manner may include a method in which, as shown in FIG. 6(B), theadhesive tape 15 is peeled off after the adhesive tape is stuck toremove the composition 11 for functional portions on the unexposedportions, thereby forming the functional portions 13 and a method inwhich, as shown in FIG. 6(C), the composition 11 for functional portionsas unnecessary portions is removed by injecting-air from an airinjection nozzle 16 to thereby enable the formation of the functionalportions 13.

Further, FIG. 7 shows a method of forming a functional element whichmethod is particularly effective when the characteristic-changeablelayer is the adhesion-changeable layer or the wettability-changeablelayer. First, as shown in FIG. 7(A), a thermal transfer body 19 preparedby laminating a heat-meltable composition layer 18 on one surface of asheet 17 is stuck to the pattern-forming body 9 in which thecharacteristic-changeable layer 5 having a pattern of thecharacteristic-changeable sections 8 is formed on the substrate 4 suchthat the heat-meltable composition layer 18 is in contact with thecharacteristic-changeable layer 5. Then, as shown in FIG. 7(B), aheating plate 20 is pressed against the thermal transfer body 19 fromthe side of the sheet 17 and heated. Then, if the thermal transfer body19 is peeled off after being cooled-as shown in FIG. 7(C), a functionalelement in which the functional portions 13 are formed along the patternof the characteristic-changeable sections 8 formed on thecharacteristic-changeable layer 5 can be obtained (see FIG. 7(D)).

Specific examples of these functional elements obtained in this mannermay include color filters and microlenses.

The aforementioned color filters are used for liquid crystal displaysand the like and have structures in which plural pixel portions of red,green, blue and the like are formed with a highly precise pattern on aglass substrate or the like. A low cost and highly precise color filtercan be produced by using the pattern-forming body of the presentinvention for the production of the color filter. Namely, for example,if the characteristic-changeable layer is the wettability-changeablelayer and this wettability-changeable layer is subjected to patternexposure, a pattern-forming body in which a pattern which has beenchanged in wettability is formed is obtained. Then, ink (composition forfunctional portions) is stuck to the sections (sections changed toink-philic regions by exposure) which has been changed in wettability byusing an ink jet device or the like and cured, whereby pixel portions(functional portions) can be formed with ease. This makes it possible toobtain a highly precise color filter using processs smaller in number.

When the functional element is a microlens, a pattern-forming bodyhaving a circular pattern which has been changed in wettability on awettability-changeable layer is produced. Then, when a composition(composition for functional portions) for forming a lens is dripped onthe section changed in wettability, the composition spreads on only theink-philic region and if the composition is further dripped, the contactangle of the liquid droplet can be changed. When this lens-formingcomposition is cured, lenses having various shapes and focal distancescan be obtained and highly precise microlens can be obtained. To explaina method of producing such a microlens with reference to FIG. 8, apattern-forming body 9 in which a circular pattern of acharacteristic-changeable section (ink-philic region) 8 is formed on acharacteristic-changeable layer (wettability-changeable layer) 5 isprepared. Then, a composition (ultraviolet-curable resin composition)for functional portions is jetted towards the pattern of the circularcharacteristic-changeable section (ink-philic region) 8 by using ajetting device 21 (see FIG. 8 (A)). This composition 11 for functionalportions (ultraviolet-curable resin composition) rises due to adifference in wettability between the ink-philic region as thecharacteristic-changeable section 8 and an ink-repellent region of theunexposed region (see FIG. 8(B)). A microlens 23 is formed by curingthis composition by using a resin-curing ultraviolet ray 22 (see FIG.8(C)).

EXAMPLES

The present invention will be hereinafter explained in more detail byway of examples.

Example 1

1. Formation of a Photocatalyst-Containing Layer-Side Substrate

30 g of isopropyl alcohol, 0.4 g of MF-160E (trademark, manufactured byTochem Products) using fluoroalkylsilane as its major component, 3 g oftrimethoxymethylsilane (manufactured by Toshiba Silicone, trademark:TSL8113) and 20 g of ST-K01 (trademark, manufactured by Ishihara SangyoInc.) which was a titanium dioxide/water dispersion as a photocatalystwere mixed and stirred at 100° C. for 20 minutes. The resulting mixturewas diluted with isopropyl alcohol to bring the total volume to threetimes the original, thereby preparing a composition for aphotocatalyst-containing layer.

The above composition was applied to a transparent substrate made ofsoda glass by a spin coater and was subjected to drying treatmentperformed at 150° C. for 30 minutes to form a transparentphotocatalyst-containing layer (thickness: 0.2 μm), thereby forming aphotocatalyst-containing layer-side substrate.

2. Formation of a Pattern-Forming Body Substrate

First, a composition for a wettability-changeable layer comprising thefollowing composition was prepared. (Percentage composition of thecomposition for a wettability-changeable layer) Silicone coating agent(manufactured by Toshiba 100 parts by weight Silicone, trademark:YSR3022, percentage composition: polyalkylsiloxane andpolyalkylhydrogensiloxane (30 wt %), methyl ethyl ketone (10 wt %) andtoluene (60 wt %)) Catalyst (manufactured by Toshiba Silicone,  4 partsby weight trademark: YC6831, percentage composition: organictin compound(40 wt %) and toluene (60 wt %)) Toluene 400 parts by weight

This composition for a wettability-changeable layer was applied to asubstrate made of soda glass by a spin coater and heated at 100° C. for10 minutes to form a wettability-changeable layer having a thickness of3 μm, thereby forming a pattern-forming body substrate.

3. Exposure

The photocatalyst-containing layer-side substrate was mounted on thewettability-changeable layer of the pattern-forming body substrate suchthat the photocatalyst-containing layer of the photocatalyst-containinglayer-side substrate was in contact with the wettability-changeablelayer. The both layers were exposed to light at an illuminance of 70mW/cm² for 60 seconds by using a mercury lamp (wavelength: 365 nm) fromthe side of the photocatalyst-containing layer to form acharacteristic-changeable section (ink-philic region). The contact angleof the wettability-changeable layer with water before and after theexposure was measured (30 seconds after water droplets were dripped frommicrosyringe) using a contact angle-measuring meter (CA-Z type,manufactured by Kyowa Kaimen Kagaku). As a result, the contact anglewith water before the exposure was 110 degrees whereas the contact anglewith water after the exposure was 7 degrees. The exposedcharacteristic-changeable sections became ink-philic regions and it wasconfirmed that a pattern based on a difference in wettability betweenthe exposed portion and the unexposed portion could be formed.

4. Formation of a Pattern

A pattern-forming body was obtained by carrying out exposure through aphotomask having a 100 μm-line & space pattern in the same manner as inthe above exposure. A red colorant having the following percentagecomposition was applied to the pattern-forming body by using a dipcoater and cured using UV rays to form a 100 μm-line & space redpattern. (Composition of the red colorant) UV-curable resin (esteracrylate resin: manufactured  10 parts by weight by Arakawa KagakuKogyo, trademark: AQ-11) Hardening initiator (1-hydroxycyclohexyl phenyl0.5 parts by weight ketone, manufactured by Ciba Speciality Chemicals,trademark: Irgacure 184) Red dye (manufactured by Tokyo Kasei,trademark: 0.5 parts by weight Rose bengale)5. Production of a Color Filter

A wettability-changeable layer was formed on a transparent substratemade of non-alkali glass in the same manner as above to obtain apattern-forming body substrate. The pattern-forming body substrate wasexposed through a negative type photomask with lines of 280 μm-openportions being arranged at a pitch of 300 μm in the same manner as inthe case of the above exposure to obtain a pattern-forming body.

A composition for each pixel portion having the following percentagecomposition was jetted to the exposed portion (characteristic-changeablesections, ink-philic regions) of the pattern-forming body by using aliquid precision jetting device (Dispenser manufactured by EED,trademark: 1500XL-15) and then subjected to heating treatment performedat 100° C. for 45 minutes to form a pixel portion consisting of a redpattern, a blue pattern and a green pattern. A two-solution mixed typethermohardening agent (manufactured by JSR, trademark: SS7265) as aprotective layer was applied to the pixel portion by using a spin coaterand then subjected to hardening treatment performed at 200° C. for 30minutes to form a protective layers thereby obtaining a color filter.(Percentage composition of the composition for the pixel portion)Pigments (Pigment Red 168, Pigment Green 36   3 parts by weight andPigment Blue 60) Nonionic surfactant (manufactured by Nikko 0.05 partsby weight Chemicals, trademark: NIKKOL BO-10TX) Polyvinyl alcohol(manufactured by Shin-Etsu  0.6 parts by weight Chemical Co. Ltd.,trademark: Shinetsu Poval AT) Water   97 parts by weight

Example 2

1. Preparation of a Photocatalyst-Containing Layer-Side Substrate and aPattern-Forming Body Substrate

A pattern-forming body substrate was prepared in the same manner as inExample 1. Thereafter, the same composition for aphotocatalyst-containing layer as that used in Example 1 was applied tothe wettability-changeable layer of the pattern-forming body substrateby a spin coater and heated at 150° C. for 30 minutes to form aphotocatalyst-containing layer with a thickness of 0.2 μm, therebypreparing a photocatalyst-containing layer-side substrate.

2. Exposure

The photocatalyst-containing layer-side substrate was exposed to lightfrom the side of the photocatalyst-containing layer in the same manneras in Example 1. Then, an adhesive tape (manufactured by Sumitomo 3M,trademark: Scotch Tape) was stuck to the photocatalyst-containing layerunder pressure and then peeled off at a rate of 1 mm/sec. to peel offthe photocatalyst-containing layer. The contact angle of thewettability-changeable layer with water before and after the exposurewas measured in the same manner as in Example 1. As a result, thecontact angle with water before the exposure was 95 degrees whereas thecontact angle with water after the exposure was 7 degrees. The exposedcharacteristic-changeable sections became ink-philic regions and it wasconfirmed that a pattern based on a difference in wettability betweenthe exposed portion and the unexposed portion could be formed.

Example 3

1. Formation of a Photocatalyst-Containing Layer-Side Substrate

15 g of ethanol, 15 g of isopropyl alcohol and 30 g of ST-K03(trademark, manufactured by Ishihara Sangyo) which was a waterdispersion of titanium dioxide as a photocatalyst were mixed and stirredat 100° C. for 20 minutes to prepare a composition for aphotocatalyst-containing layer. This composition was applied to atransparent substrate made of soda lime glass by a dip coater and wassubjected to heat treatment performed at 150° C. for 10 minutes to forma transparent photocatalyst-containing film (thickness: 0.2 μm), therebyforming a photocatalyst-containing layer-side substrate.

2. Formation of a Pattern-Forming Body Substrate

2 wt % of a fluorine type nonionic surfactant ZONYL FSN (trademark,manufactured by Du Pont) was mixed in isopropanol to prepare acomposition for a decomposition-removable layer. This composition for adecomposition-removable layer was applied to a transparent substratemade of soda lime glass by a spin coater and heated at 50° C. for 10minutes to form a decomposition-removable layer having a thickness of0.1 μm, thereby forming a pattern-forming body substrate.

3. Exposure

The photocatalyst-containing layer-side substrate was mounted on thedecomposition-removable layer of the pattern-forming body substrate suchthat the photocatalyst-containing layer of the photocatalyst-containinglayer-side substrate was in contact with the decomposition-removablelayer. The both layers were exposed to light at an illuminance of 70mW/cm for 2 minutes by using a mercury lamp (wavelength: 365 nm) fromthe side of the photocatalyst-containing layer to decompose and removethe decomposition-removable layer thereby exposing the substrate glass.The contact angle with water before and after the exposure,specifically, the contact angle of the surface of thedecomposition-removable layer with water and the contact angle of theexposed glass surface after the exposure were measured in the samemanner as in Example 1. As a result, the contact angle of the surface ofthe decomposition-removable layer with water was 71 degrees whereas thecontact angle, with water, of the glass surface exposed after theexposure was 9 degrees. It was confirmed that a pattern based on adifference in wettability between the exposed portion and the unexposedportion could be formed.

4. Formation of a Microlens

A pattern-forming body was obtained by carrying out exposure through anegative type photomask in which plural 200 μm-circular opening portionsare arranged at intervals of 100 μm in the same manner as in the aboveexposure. A composition for a microlens having the following percentagecomposition was jetted to the exposed portion of the pattern-formingbody at a jetting rate of 0.0001 ml by using a liquid precision jettingdevice (Dispenser manufactured by EED, trademark: 1500XL-15) and thenUV-cured to obtain a microlens array having a diameter of 200 μm and afocal distance of 500 μm. (Percentage composition of the composition forthe microlens) UV-curable resin (ester acrylate resin, manufactured  10parts by weight by Arakawa Kagaku Kogyo, trademark: AQ-11) Hardeninginitiator (1-hydroxycyclohexyl phenyl 0.5 parts by weight ketone,manufactured by Ciba Speciality Chemicals, trademark: Irgacure 184)

The present invention is not limited to the aforementioned embodiments.These embodiments are typical examples and any invention havingsubstantially the same structure and the same action effects as thetechnical spirits described in the scope of the claim of the patent ofthe present invention is embraced in the technical scope of the presentinvention.

For instance, the foregoing explanations are offered using examples inwhich the functional elements are all formed on the pattern-formingbody. However, the present invention is not limited to these examples.For example, the following structure may be adopted. Specifically, asshown in FIG. 9, first the characteristic-changeable layer 5 is formedon the substrate 4 in the same manner as in the above explanations andthe functional portion 13 is formed along the pattern of thecharacteristic-changeable section of the characteristic-changeable layer5 (see FIG. 9(A)). Next, an element forming substrate 24 is allowed tostick to the functional portion 13 such that it is in contact with thefunctional portion 13 (see FIG. 9(B)). Then, the functional portion 13is transferred to the element forming substrate 24 to form a functionalelement. As mentioned above, the functional element is not limited tothose formed on the pattern-forming body.

1. A functional element comprising an adhesion-changeable layer and afunctional portion, wherein the adhesion-changeable layer is a layerchanging an adhesion by an action of a photocatalyst and excluding aphotocatalyst-containing layer; and the functional portion is disposedon a section corresponding to a pattern formed on a pattern-forming bodyhaving the pattern with the adhesion of the adhesion-changeable layerchanged.
 2. The functional element according to claim 1, wherein thefunctional portion is a metal.
 3. The functional element according toclaim 1, wherein the functional portion is formed on a section with ahigh adhesion of the adhesion-changeable layer.
 4. A color filtercomprising a pixel portion, wherein the pixel portion is the functionalportion of the functional element as claimed in claim
 3. 5. A microlenscomprising a lens, wherein the lens is the functional portion of thefunctional element as claimed in claim 3.